Flooring system and method for installing involving a corrugated member and a panel flooring member

ABSTRACT

A first description of a flooring system includes; a corrugated member containing metal and having ribs and valleys; a panel flooring member positioned over the ribs; and a fastener attaching the flooring member to one of the ribs. Each rib has a maximum transverse width of three inches, and each valley has a maximum top transverse width of three inches with such valley-to-rib width ratio having a range from 1.0 to 3.5. A second description of a flooring system includes a panel flooring member and a corrugated member similar to those of the first flooring system, but without the dimensional specifications of the ribs and valleys of the first flooring system, and includes a screw attaching the flooring member to the rib, wherein the screw has a pair of upper wings and a pair of lesser-protruding lower wings. Methods are disclosed for installing the described flooring systems.

TECHNICAL FIELD

The present invention relates generally to flooring systems and methodsfor installing flooring systems and more particularly to those systemsand methods involving a corrugated member and a panel flooring member.

BACKGROUND OF THE INVENTION

Conventional flooring systems include mezzanine flooring systems whichprovide one or more floor levels between the main floor and the mainceiling and are used, for example, in warehouses. The mezzanine floortypically is used by people with or without wheeled carts or wheeledpallet jacks to store goods on, and remove goods from, one or more shelflevels accessible from the mezzanine floor.

Conventional flooring-panel mezzanine flooring systems use 20 to 16 gagecorrugated steel B or N type roof deck having parallel andlongitudinally extending ribs and valleys. B-type roof deck has each ribhave a transverse width equal to 3.50 inches and each valley have a toptransverse width equal to 2.50 inches with a height of each rib abovethe bottom of each adjoining valley equal to 1.5 inches. N-type roofdeck has each rib have a transverse width equal to 5.38 inches and eachvalley have a top transverse width equal to 2.62 inches with a height ofeach rib above the bottom of each adjoining valley equal to 3 inches. Atleast some of the valleys of the B or N type roof deck are attached to astructural mezzanine substructure or are attached to rack-supported orshelving-supported substructure at a height above a main floor.Tongue-and-groove wood-product flooring panels are then placed over theribs of the B or N type roof deck. Typically, topside screws are used toattach a flooring panel to at least some of the ribs of the B or N typeroof deck. Attachment by bottom-side screws is also known. U.S. Pat. No.6,718,720 teaches attachment by a bottom-side radially-expandingfastener such as a rivet. Another flooring-panel mezzanine flooringsystem is known which uses a corrugated member having parallel andlongitudinally extending 6 inch wide ribs and six inch wide valleys witha rib height of 7 to 8 inches, wherein each rib has 3 or 4longitudinally-extending surface grooves which are about one-half of aninch across and about three-eighths of an inch deep.

A known topside screw design for attaching a wood-product flooring panelto a steel rib of B or N type roof deck includes in serial flowrelationship a counter-sinkable head, a pair of opposing upper wings tohelp cut the flooring panel to counter-sink the head, a threaded portionto threadably engage the rib, a non-threaded portion at leastsubstantially equal in length to the roof deck thickness to preventthread-caused roof deck lift-up as a drill bit encounters the steel rib,and the drill bit to drill through the roof deck and then the rib.

A known topside screw design for attaching a wood-product flooring panelto a thick, non-corrugated steel, heavy gage support member includes inserial flow relationship a counter-sinkable head, a pair of opposingupper wings to help cut the flooring panel to counter-sink the head, athreaded portion to threadably engage the rib, a pair of opposing,less-radially-extending lower wings to widen the hole to prevent thethreaded portion from threadably engaging the flooring panel to preventthread-caused flooring panel lift-up as a drill bit encounters the steelsupport member, and the drill bit to drill through the roof deck andthen the support member, wherein the lower wings break off when theyencounter the thick, heavy gage support member.

Conventional concrete mezzanine flooring systems pour concrete overcomposite or non-composite steel deck, such as 18 to 24 gage,non-composite 1.5C type deck having parallel and longitudinallyextending ribs and valleys. The 1.5C type deck has each rib have atransverse width equal to 1.75 inches and each valley have a toptransverse width equal to 4.25 inches with a height of each rib abovethe bottom of each adjoining valley equal to 1.5 inches. Composite steeldeck is fabricated to bond to the concrete so that the concrete andsteel act together as a composite section. Non-composite steel deckserves strictly as a form for the concrete requiring reinforcing bars tobe placed in the slab. Typically, enough concrete is poured to extendseveral inches above the ribs.

Conventional roofs include exposed corrugated roof deck, such as 16 to24 gage steel 1.0E type roof deck having parallel and longitudinallyextending ribs and valleys. The 1.0E type roof deck has each rib have atransverse width equal to 1.13 inches and each valley have a toptransverse width equal to 2.87 inches with a height of each rib abovethe bottom of each adjoining valley equal to 1.0 inches.

What is needed is an improved flooring system and method for installinginvolving a corrugated member and a panel flooring member.

SUMMARY OF THE INVENTION

A first method of the invention is for installing a flooring system andincludes steps a) through e). Step a) includes obtaining a corrugatedmember having a plurality of substantially parallel and longitudinallyextending ribs and valleys, wherein the corrugated member containsmetal, wherein each rib has a transverse width of up to three inches,wherein each valley has a top transverse width of up to three inches,wherein a ratio of the transverse top width of each valley to thetransverse width of each adjoining rib has a range from 1.0 to 3.5,wherein each valley has a bottom, and wherein each rib has asubstantially equal height above the bottom of each adjoining valley.Step b) includes obtaining a panel flooring member having top and bottomsides. Step c) includes positioning the panel flooring member over andin contact with the corrugated member with the bottom side of the panelflooring member contacting a multiplicity of the ribs of the corrugatedmember. Step d) includes obtaining a fastener. Step e) includesattaching the panel flooring member to one of the ribs of the corrugatedmember using the fastener.

A first expression of an embodiment of the invention is for a flooringsystem including a corrugated member, a panel flooring member, and afastener. The corrugated member has a plurality of substantiallyparallel and longitudinally extending ribs and valleys, and thecorrugated member contains metal. Each rib has a transverse width of upto three inches, and each valley has a top transverse width of up tothree inches. A ratio of the transverse top width of each valley to thetransverse width of each adjoining rib has a range from 1.0 to 3.5. Eachvalley has a bottom, and each rib has a substantially equal height abovethe bottom of each adjoining valley. The panel flooring member has topand bottom sides. The panel flooring member is positioned over and incontact with the corrugated member with the bottom side of the panelflooring member contacting a multiplicity of the ribs of the corrugatedmember. The fastener attaches the panel flooring member to one of theribs of the corrugated member.

A second method of the invention is for installing a flooring system andincludes steps a) through e). Step a) includes obtaining a corrugatedmember having a plurality of substantially parallel and longitudinallyextending ribs and valleys, wherein the corrugated member containsmetal, wherein each valley has a bottom, and wherein each rib has asubstantially equal height above the bottom of each adjoining valley.Step b) includes obtaining a panel flooring member having top and bottomsides, wherein the panel flooring member has a substantially constantthickness. Step c) includes positioning the panel flooring member overand in contact with the corrugated member with the bottom side of thepanel flooring member contacting a multiplicity of the ribs of thecorrugated member. Step d) includes obtaining a screw including inserial flow relationship a counter-sinkable head, a pair of opposingupper wings, a threaded portion, a pair of opposing lower wings, and adrill bit, wherein the lower wings radially extend more than the drillbit, at least as much as the threaded portion, and less than the upperwings, and wherein the upper wings radially extend more than thethreaded portion and less than the head. Step e) includes attaching thepanel flooring member to one of the ribs of the corrugated member usingthe screw by inserting the screw first into the top side of the panelflooring member, then out through the bottom side of the panel flooringmember, and then into the one rib of the corrugated member with thethreaded portion threadably engaged with the one rib.

A second expression of an embodiment of the invention is for a flooringsystem including a corrugated member, a panel flooring member, and ascrew. The corrugated member has a plurality of substantially paralleland longitudinally extending ribs and valleys, and the corrugated membercontains metal. Each valley has a bottom, and each rib has asubstantially equal height above the bottom of each adjoining valley.The panel flooring member has top and bottom sides. The panel flooringmember has a substantially constant thickness. The panel flooring memberis positioned over and in contact with the corrugated member with thebottom side of the panel flooring member contacting a multiplicity ofthe ribs of the corrugated member. The panel flooring member includes athrough hole extending from the top side to the bottom side. The screwincludes in serial flow relationship a head positioned in the throughhole and countersunk in the top side of the panel flooring member, apair of opposing upper wings positioned in the through hole, a threadedportion threadably engaged with one of the ribs of the corrugated memberbut not threadably engaged with the panel flooring member, a pair oflocations of broken-off opposing lower wings, and a drill bit positionedbelow the one rib. The through hole has a diameter below the upper wingswhich radially extends more than the drill bit, at least as much as thethreaded portion, and less than the upper wings. The upper wingsradially extend more than the threaded portion and less than the head.

Several benefits and advantages are derived from one or more or all ofthe methods and expressions of an embodiment of the invention. In oneexample involving the first method and the first expression of anembodiment having the detailed dimensional description of the corrugatedmember, the configuration of the geometry of the corrugated memberallows a thinner corrugated member to support a desired dynamic rollingload on the panel flooring member, using conventional topside screwfasteners, thereby substantially reducing the total cost of the flooringsystem without reducing the performance of the flooring system. In oneexample involving the second method and the second expression of anembodiment having the detailed description of the screw used to attachthe panel flooring member to one of the ribs of the corrugated member,the configuration of the geometry of the screw allows a shorter screw tobe used while still preventing panel-flooring-member lift-up, therebypreventing, in short height rib flooring systems, undesired contact of ascrew positioned directly over a solid portion of the underlyingsubstructure.

SUMMARY OF THE DRAWINGS

FIG. 1 is a cross-sectional, end elevational view of an embodiment of aflooring system of the invention showing a topside-screw-type fastenerattachment of the panel flooring member of the flooring system to onerib of the corrugated member of the flooring system with the corrugatedmember supported on a solid portion of a substructure;

FIG. 2 is a top planar view of the corrugated member of FIG. 1 beforethe panel flooring member is disposed over the corrugated member;

FIG. 3 is an end elevational view of the corrugated member of FIG. 2;

FIG. 4 is an end elevational view of a different corrugated member whoseribs have undulations;

FIG. 5 is an end elevational view of a different corrugated member whoseribs have top indentations;

FIG. 6 is an end elevational view of a different corrugated memberhaving a curved edge joining each rib to each adjoining valley;

FIG. 7 is a side elevational view of the screw-type fastener of FIG. 1before it is used to attach the panel flooring member to the one rib ofthe corrugated member; and

FIG. 8 is an enlarged view of a portion of FIG. 1 showing the screw-typefastener attaching the panel flooring member to the one rib of thecorrugated member.

DETAILED DESCRIPTION

It is noted that like parts are numbered alike throughout the figures.Referring now to the drawings, FIGS. 1-3 and 7-8 show an embodiment ofthe present invention. A first expression of the embodiment of FIGS. 1-3and 7-8 is for a flooring system 10 including a corrugated member 12, apanel flooring member 14, and a fastener 16. The corrugated member 12has a plurality of substantially parallel and longitudinally extendingribs 18 and valleys 20, and the corrugated member 12 contains metal.Each rib 18 has a transverse width 22 of up to three inches, and eachvalley 20 has a top transverse width 24 of up to three inches. A ratioof the transverse top width 24 of each valley 20 to the transverse width22 of each adjoining rib 18 has a range from 1.0 to 3.5. Each valley 20has a bottom 26, and each rib 18 has a substantially equal height 28above the bottom 26 of each adjoining valley 20. The panel flooringmember 14 has top and bottom sides 30 and 32. The panel flooring member14 is disposed over and in contact with the corrugated member 12 withthe bottom side 32 of the panel flooring member 14 contacting amultiplicity of the ribs 18 of the corrugated member 12. The fastener 16attaches the panel flooring member 14 to one of the ribs 18 of thecorrugated member 12.

In one application of the first expression of the embodiment of FIGS.1-3 and 7-8, the top side 30 of the flooring panel member 14 is exposedto at least one of walking floor traffic and rolling floor traffic. Inthe same or a different application, the ribs 18 are substantiallyidentical and the valleys 20 are substantially identical, and thecorrugated member 12 has a substantially constant thickness and thepanel flooring member 14 has a substantially constant thickness.

In a first enablement of the first expression of the embodiment of FIGS.1-3 and 7-8, the corrugated member 12 is a C type galvanized or paintedsteel deck available from Vulcraft (a division of Nucor Corporation ofCharlotte, N.C.), and the panel flooring member 14 is a ResinDek® panelavailable from Cornerstone Specialty Wood Products of Cincinnati, Ohio.

In one construction of the first expression of the embodiment of FIGS.1-3 and 7-8, the ribs 18 and the bottom 26 of the valleys 20 aresubstantially planar and parallel. In one variation, the corrugatedmember 12 consists essentially of steel, has a thickness ofsubstantially 24 gage, and has a yield strength of substantially 80 ksi(thousand pounds per square inch), and the top side 30 of the panelflooring member 14 is exposed to rolling floor traffic having a dynamicrolling load of at least 350 psi (pounds per square inch).

Applicants tested an example of the flooring system having aconventional screw as the fastener, a ResinDek® LD panel as the panelflooring member 14, and a 22 gage 10C type deck as the corrugated member12. Over 40,000 cycles of simulated repeat pallet jack wheel trafficwere run to simulate 10 years of pallet jack traffic with the equivalentof 2,000 pounds on a pallet jack with a dynamic rolling load of 350 psi.There were no failures of the flooring system upon completion of thecycle testing. Applicants have had made a limited number of the screws44 of FIG. 7 and have tested fifteen of them to test attaching aResinDek® LD panel (as the panel flooring member) to a 22 gage 1.0C typedeck (as the corrugated member). There were no failures in attaching theResinDek® LD panel to the 22 gage 1.0C type deck using the screw of FIG.7. Applicants have yet to undertake the cycle testing of the flooringsystem 10 having the screws 44 of FIG. 7 as was done with the flooringsystem having the conventional screws.

In a first different construction, as shown in FIG. 4, the corrugatedmember 112 is a monolithic member, and each rib 118 has a plurality ofundulations 134. In a second different construction, as shown in FIG. 5,the corrugated member 212 is a monolithic member, and each rib 218 has aplurality of top indentations 236. In a third different construction, asshown in FIG. 6, the corrugated member 312 is a monolithic member havinga curved edge 338 joining each rib 318 to each adjoining valley 320.

It is noted that in FIGS. 1-3 and 7-8, a valley 20 also includes twosides 40 joining the bottom 26 of the valley 20 to the two adjoiningribs 18. Note the same is true for the two sides 140 seen in FIG. 4, thetwo sides 240 seen in FIG. 5, and the two sides 340 seen in FIG. 6.

In any construction, such as those shown in FIGS. 3-6, it is noted thatthe terminology “transverse width” of a rib is defined to be the actualtransverse width of the rib when the rib meets the two adjoining valleysides along a substantially straight edge (such as straight edge 42 seenend-on and shown along with the transverse width 22 in FIG. 3) and isdefined to be the transverse distance the panel flooring member contactsand is within one-eighth inch of contacting the two adjoining valleysides when the rib meets the two adjoining valley sides along a curvededge (such as curved edge 338 shown along with the transverse width 322in FIG. 6).

Likewise, it is noted that the terminology “top transverse width” of avalley is defined to be the actual transverse distance between the topsof the two sides 40 of the valley 40 when the sides of the valley meetthe two adjoining ribs along a substantially straight edge (such asstraight edge 42 seen end-on and shown along with the top transversewidth 24 in FIG. 3) and is defined to be the transverse distance betweenthe two sides at points along the two sides which are one-eighth inchfrom the panel flooring member when the two sides of the valley meet thetwo adjoining ribs along a curved edge (such as curved edge 338 shownalong with the top transverse width 324 in FIG. 6).

In one enablement of the first expression of the embodiment of FIGS. 1-3and 7-8, the fastener 16 is a screw 44 having an upper portion 46 and alower portion 48. The upper portion 46 is disposed in the panel flooringmember 14 and extends substantially the entire thickness of the panelflooring member 14. The lower portion 48 threadably engages one of theribs 18 of the corrugated member 12. Other types of fasteners, includingadhesives, are left to the artisan.

In one variation, the panel flooring member 14 includes a through hole50 extending from the top side 30 to the bottom side 32. In oneillustration, the screw 44 includes in serial flow relationship a head52 disposed in the through hole 50 and countersunk in the top side 30 ofthe panel flooring member 14, a pair of opposing upper wings 54 disposedin the through hole 50, a threaded portion 56 threadably engaged withthe one rib 18 but not threadably engaged with the panel flooring member14, a pair of locations 58 of broken-off opposing lower wings 60, and adrill bit 62 disposed below the one rib 18. The through hole 50 has adiameter below the upper wings 54 which radially extends more than thedrill bit 62, at least as much as the threaded portion 56, and less thanthe upper wings 54. The upper wings 54 radially extend more than thethreaded portion 56 and less than the head 52. In one example, the screw44 has a length which is less than the thickness of the panel flooringmember 14 plus the height 28 of the one rib 18. In another illustration,the design of the screw is left to the artisan.

A first method of the invention is for installing a flooring system 10and includes steps a) through e). Step a) includes obtaining acorrugated member 12 having a plurality of substantially parallel andlongitudinally extending ribs 18 and valleys 20, wherein the corrugatedmember 12 contains metal, wherein each rib 18 has a transverse width 22of up to three inches, wherein each valley 20 has a top transverse width24 of up to three inches, wherein a ratio of the transverse top width 24of each valley 20 to the transverse width 22 of each adjoining rib 18has a range from 1.0 to 3.5, wherein each valley 20 has a bottom 26, andwherein each rib 18 has a substantially equal height 28 above the bottom26 of each adjoining valley 20. Step b) includes obtaining a panelflooring member 14 having top and bottom sides 30 and 32. Step c)includes disposing the panel flooring member 14 over and in contact withthe corrugated member 12 with the bottom side 32 of the panel flooringmember 14 contacting a multiplicity of the ribs 18 of the corrugatedmember 12. Step d) includes obtaining a fastener 16. Step e) includesattaching the panel flooring member 14 to one of the ribs 18 of thecorrugated member 12 using the fastener 16.

In one example of the first method, additional fasteners (not shown) areused for additional attachments of the panel flooring member 14 to theone, and/or to others, of the ribs 18. In the same or a differentexample, the first method also includes, after step e), exposing the topside 30 of the panel flooring member 14 to at least one of walking floortraffic and rolling floor traffic.

In one application of the first method, the ribs 18 are substantiallyidentical and the valleys 20 are substantially identical, and thecorrugated member 12 has a substantially constant thickness and thepanel flooring member 14 has a substantially constant thickness.

In one implementation of the first method, the ribs 18 and the bottom 26of the valleys 20 are substantially planar and parallel. In onevariation, the corrugated member 12 consists essentially of steel, has athickness of substantially 24 gage, and has a yield strength ofsubstantially 80 ksi, and the first method includes, after step e),exposing the top side 30 of the panel flooring member 14 to rollingfloor traffic having a dynamic rolling load of at least 350 psi.

In a first different implementation, as shown in FIG. 4, the corrugatedmember 112 is a monolithic member, and each rib 118 has a plurality ofundulations 134. In a second different implementation, as shown in FIG.5, the corrugated member 212 is a monolithic member, and each rib 218has a plurality of top indentations 236. In a third differentimplementation, as shown in FIG. 6, the corrugated member 312 is amonolithic member having a curved edge 338 joining each rib 318 to eachadjoining valley 320.

In a first enablement of the first method, the fastener 16 is a screw 44having an upper portion 46 and a lower portion 48. The upper portion 46is disposed in the panel flooring member 14 and extends substantiallythe entire thickness of the panel flooring member 14. The lower portion48 threadably engages one of the ribs 18 of the corrugated member 12.Other types of fasteners, including adhesives, are left to the artisan.

In a first variation of the first enablement of the first method, thescrew 44 includes in serial flow relationship a counter-sinkable head52, a pair of opposing upper wings 54, a threaded portion 56, a pair ofopposing lower wings 60, and a drill bit 62. The threaded portion 56radially extends more than the drill bit 62. The lower wings 60 radiallyextend more than the drill bit 62, at least as much as the threadedportion 56, and less than the upper wings 54. The upper wings 54radially extend more than the threaded portion 56 and less than the head52. The lower wings 60 are adapted to remain intact while passingthrough the panel flooring member 14 and to break off upon encounteringthe one rib 18 allowing the threaded portion 56 to threadably engage theone rib 18 during step e). In one example, the screw 44 has a lengthwhich is less than the thickness of the panel flooring member 14 plusthe height of the one rib 18.

In a second variation of the first enablement of the first method, thescrew 44 includes in serial flow relationship a counter-sinkable head52, a pair of opposing upper wings 54, a threaded portion 56, a pair ofopposing lower wings 60, and a drill bit 62. The threaded portion 56radially extends more than the drill bit 62. The lower wings 60 radiallyextend more than the drill bit 62, at least as much as the threadedportion 56, and less than the upper wings 54. The upper wings 54radially extend more than the threaded portion 56 and less than the head52. The lower wings 60 are adapted to remain intact while passingthrough only a portion of the panel flooring member 14 and to break offin the panel flooring member 14 before encountering the one rib 18allowing the threaded portion 56 to threadably engage the one rib 18during step e). In one example, the screw 44 has a length which is lessthan the thickness of the panel flooring member 14 plus the height ofthe one rib 18.

In one procedure involving adapting the screw 44 to have the lower wings60 break off where desired, design of the thickness and/or thelongitudinal extent of the lower wings 60 should be able to bedetermined by experimentation. Thinner and/or longitudinally shorterlower wings 60 should be able to break off in a panel flooring member 14of a specified density and still prevent panel-flooring-member lift-up.Thicker and/or longitudinally longer lower wings 60 should be able topass completely through the panel flooring member 14 of a specifieddensity and break off upon encountering the one rib 18 unless the onerib 18 is too thin which could result in the lower wings creating a holein the rib as wide or wider than the threaded portion 56 preventing thethreaded portion 56 from threadably engaging the one rib 18.

In a third variation of the first enablement of the first method, thedesign of the screw is left to the artisan.

A second expression of the embodiment of FIGS. 1-3 and 7-8 is for aflooring system 10 including a corrugated member 12, a panel flooringmember 14, and a screw 44. The corrugated member 12 has a plurality ofsubstantially parallel and longitudinally extending ribs 18 and valleys20, and the corrugated member 12 contains metal. Each valley 20 has abottom 26, and each rib 18 has a substantially equal height 28 above thebottom 26 of each adjoining valley 20. The panel flooring member 14 hastop and bottom sides 30 and 32. The panel flooring member 14 has asubstantially constant thickness. The panel flooring member 14 isdisposed over and in contact with the corrugated member 12 with thebottom side 32 of the panel flooring member 14 contacting a multiplicityof the ribs 18 of the corrugated member 12. The panel flooring member 14includes a through hole 50 extending from the top side 30 to the bottomside 32.

In the second expression, the screw 44 includes in serial flowrelationship a head 52 disposed in the through hole 50 and countersunkin the top side 30 of the panel flooring member 14, a pair of opposingupper wings 54 disposed in the through hole 50, a threaded portion 56threadably engaged with one of the ribs 18 of the corrugated member 12but not threadably engaged with the panel flooring member 14, a pair oflocations 58 of broken-off opposing lower wings 60, and a drill bit 62disposed below the one rib 18. The through hole 50 has a diameter belowthe upper wings 54 which radially extends more than the drill bit 62, atleast as much as the threaded portion 56, and less than the upper wings54. The upper wings 54 radially extend more than the threaded portion 56and less than the head 52.

In one example of the second expression of the embodiment of FIGS. 1-3and 7-8, the screw 44 has a length which is less than the thickness ofthe panel flooring member 14 plus the height of the one rib 18. In oneapplication of the second expression of the embodiment of FIGS. 1-3 and7-8, the top side 30 of the flooring panel member 14 is exposed to atleast one of walking floor traffic and rolling floor traffic. In onevariation, the corrugated member 12 is B-type roof deck or N-type roofdeck. In another variation, the corrugated member 12 is C-type deck.

A second method of the invention is for installing a flooring system 10and includes steps a) through e). Step a) includes obtaining acorrugated member 12 having a plurality of substantially parallel andlongitudinally extending ribs 18 and valleys 20, wherein the corrugatedmember 12 contains metal, wherein each valley 20 has a bottom 26, andwherein each rib 18 has a substantially equal height 28 above the bottom26 of each adjoining valley 20. Step b) includes obtaining a panelflooring member 14 having top and bottom sides 30 and 32, wherein thepanel flooring member 14 has a substantially constant thickness. Step c)includes disposing the panel flooring member 14 over and in contact withthe corrugated member 12 with the bottom side 32 of the panel flooringmember 14 contacting a multiplicity of the ribs 18 of the corrugatedmember 12.

Step d) includes obtaining a screw 44 including in serial flowrelationship a counter-sinkable head 52, a pair of opposing upper wings54, a threaded portion 56, a pair of opposing lower wings 60, and adrill bit 62, wherein the lower wings 60 radially extend more than thedrill bit 62, at least as much as the threaded portion 56, and less thanthe upper wings 54, and wherein the upper wings 54 radially extend morethan the threaded portion 56 and less than the head 52. Step e) includesattaching the panel flooring member 14 to one of the ribs 18 of thecorrugated member 12 using the screw 44 by inserting the screw 44 firstinto the top side 30 of the panel flooring member 14, then out throughthe bottom side 32 of the panel flooring member 14, and then into theone rib 18 of the corrugated member 12 with the threaded portion 56threadably engaged with the one rib 18.

In one example of the second method, the screw 44 has a length which isless than the thickness of the panel flooring member 14 plus the heightof the ribs 18. In the same or a different example, additional fasteners(not shown) are used for additional attachments of the panel flooringmember 14 to the one, and/or to others, of the ribs 18. In the same or adifferent example, the second method also includes, after step e),exposing the top side 30 of the panel flooring member 14 to at least oneof walking floor traffic and rolling floor traffic. In one variation,the corrugated member 12 is B-type roof deck or N-type roof deck. Inanother variation, the corrugated member 12 is C-type deck.

In a first variation of the second method, the lower wings 60 areadapted to remain intact in the panel flooring member 14 and to breakoff upon encountering the one rib 18 of the corrugated member 12.

In a second variation of the second method, the lower wings 60 areadapted to remain intact while passing through only a portion of thepanel flooring member 14 and to break off in the panel flooring member14 before encountering the one rib 18 of the corrugated member 12.

In one arrangement of either or both of the methods and either or bothof the expressions the embodiment of FIGS. 1-3 and 7-8, the one rib 18is attached to an underlying mezzanine-flooring-system substructure 64,and the flooring system 10 is a mezzanine flooring system.

In a first choice of materials for one or more or all of the methods andexpressions of an embodiment of the invention, and differentconstructions thereof, the panel flooring member (such as panel flooringmember 14) contains wood such as compressed wood fibers such as aResinDek® panel available from Cornerstone Specialty Wood Products ofCincinnati, Ohio. In a second choice, the panel flooring member containsresin-impregnated non-wood fibers. In a third choice, the panel flooringmember contains plastic. In a fourth choice, the panel flooring memberis a pre-cast concrete panel. In a fifth choice, the panel flooringmember contains plywood veneers, or oriented strand board chips pressedtogether under heat and pressure with wax and resin binders. In a sixthchoice, the panel flooring member contains medium density fiberboardfibers or industrial particleboard wood particles. Other choices ofmaterials for the panel flooring member, and choices (such as, but notlimited to, steel) for the metal contained in the metal-containingcorrugated member 12, 112, 212, and 312, are left to those skilled inthe art.

Several benefits and advantages are derived from one or more or all ofthe methods and expressions of an embodiment of the invention. In oneexample involving the first method and the first expression of anembodiment having the detailed dimensional description of the corrugatedmember, the configuration of the geometry of the corrugated memberallows a thinner corrugated member to support a desired dynamic rollingload on the panel flooring member, using conventional topside screwfasteners, thereby substantially reducing the total cost of the flooringsystem without reducing the performance of the flooring system. In oneexample involving the second method and the second expression of anembodiment having the detailed description of the screw used to attachthe panel flooring member to one of the ribs of the corrugated member,the configuration of the geometry of the screw allows a shorter screw tobe used while still preventing panel-flooring-member lift-up, therebypreventing, in short height rib flooring systems, undesired contact of ascrew positioned directly over a solid portion of the underlyingsubstructure.

The foregoing description of several methods and several expressions ofan embodiment of the invention has been presented for purposes ofillustration. It is not intended to be exhaustive or to limit theinvention to the precise form and steps disclosed, and obviously manymodifications and variations are possible in light of the aboveteaching. It is intended that the scope of the invention be defined bythe claims appended hereto.

1. A method for installing a flooring system comprising the steps of: a)obtaining a corrugated member having a plurality of substantiallyparallel and longitudinally extending ribs and valleys, wherein thecorrugated member contains metal, wherein each rib has a transversewidth of up to three inches, wherein each valley has a top transversewidth of up to three inches, wherein a ratio of the transverse top widthof each valley to the transverse width of each adjoining rib has a rangefrom 1.0 to 3.5, wherein each valley has a bottom, and wherein each ribhas a substantially equal height above the bottom of each adjoiningvalley; b) obtaining a panel flooring member having top and bottomsides; c) disposing the panel flooring member over and in contact withthe corrugated member with the bottom side of the panel flooring membercontacting a multiplicity of the ribs of the corrugated member; d)obtaining a fastener; and e) attaching the panel flooring member to oneof the ribs of the corrugated member using the fastener.
 2. The methodof claim 1, also including, after step e), exposing the top side of thepanel flooring member to at least one of walking floor traffic androlling floor traffic.
 3. The method of claim 1, wherein the ribs aresubstantially identical and the valleys are substantially identical, andwherein the corrugated member has a substantially constant thickness andthe panel flooring member has a substantially constant thickness.
 4. Themethod of claim 3, wherein the corrugated member consists essentially ofsteel, has a thickness of substantially 24 gage, and has a yieldstrength of substantially 80 ksi, and including, after step e), exposingthe top side of the panel flooring member to rolling floor traffichaving a dynamic rolling load of at least 350 psi.
 5. The method ofclaim 3, wherein the corrugated member is a monolithic member, andwherein each rib has a plurality of undulations.
 6. The method of claim3, wherein the corrugated member is a monolithic member, and whereineach rib has a plurality of top indentations.
 7. The method of claim 3,wherein the corrugated member is a monolithic member having a curvededge joining each rib to each adjoining valley.
 8. The method of claim3, wherein the fastener obtained in step d) is a screw, and wherein stepe) inserts the screw first into the top side of the panel flooringmember, then out through the bottom side of the panel flooring member,and then into the one rib of the corrugated member.
 9. The method ofclaim 8, wherein the screw includes in serial flow relationship acounter-sinkable head, a pair of opposing upper wings, a threadedportion, a pair of opposing lower wings, and a drill bit, wherein thethreaded portion radially extends more than the drill bit, wherein thelower wings radially extend more than the drill bit, at least as much asthe threaded portion, and less than the upper wings, wherein the upperwings radially extend more than the threaded portion and less than thehead, and wherein the lower wings are adapted to remain intact whilepassing through the panel flooring member and to break off uponencountering the one rib allowing the threaded portion to threadablyengage the one rib during step e).
 10. The method of claim 9, whereinthe screw has a length which is less than the thickness of the panelflooring member plus the height of the one rib.
 11. The method of claim8, wherein the screw includes in serial flow relationship acounter-sinkable head, a pair of opposing upper wings, a threadedportion, a pair of opposing lower wings, and a drill bit, wherein thethreaded portion radially extends more than the drill bit, wherein thelower wings radially extend more than the drill bit, at least as much asthe threaded portion, and less than the upper wings, wherein the upperwings radially extend more than the threaded portion and less than thehead, and wherein the lower wings are adapted to remain intact whilepassing through only a portion of the panel flooring member and to breakoff in the panel flooring member before encountering the one riballowing the threaded portion to threadably engage the one rib duringstep e).
 12. The method of claim 11, wherein the screw has a lengthwhich is less than the thickness of the panel flooring member plus theheight of the one rib.
 13. A flooring system comprising: a) a corrugatedmember having a plurality of substantially parallel and longitudinallyextending ribs and valleys, wherein the corrugated member containsmetal, wherein each rib has a transverse width of up to three inches,wherein each valley has a top transverse width of up to three inches,wherein a ratio of the transverse top width of each valley to thetransverse width of each adjoining rib has a range from 1.0 to 3.5,wherein each valley has a bottom, and wherein each rib has asubstantially equal height above the bottom of each adjoining valley; b)a panel flooring member having top and bottom sides, wherein the panelflooring member is disposed over and in contact with the corrugatedmember with the bottom side of the panel flooring member contacting amultiplicity of the ribs of the corrugated member; and c) a fastenerattaching the panel flooring member to one of the ribs of the corrugatedmember.
 14. The flooring system of claim 13, wherein the top side of theflooring panel member is exposed to at least one of walking floortraffic and rolling floor traffic.
 15. The flooring system of claim 13,wherein the ribs are substantially identical and the valleys aresubstantially identical, and wherein the corrugated member has asubstantially constant thickness and the panel flooring member has asubstantially constant thickness.
 16. The flooring system of claim 15,wherein the corrugated member consists essentially of steel, has athickness of substantially 24 gage, and has a yield strength ofsubstantially 80 ksi, and wherein the top side of the panel flooringmember is exposed to rolling floor traffic having a dynamic rolling loadof at least 350 psi.
 17. The flooring system of claim 15 wherein thecorrugated member is a monolithic member, and wherein each rib has aplurality of undulations.
 18. The flooring system of claim 15 whereinthe corrugated member is a monolithic member, and wherein each rib has aplurality of top indentations.
 19. The flooring system of claim 15,wherein the corrugated member is a monolithic member having a curvededge joining each rib to each adjoining valley.
 20. The flooring systemof claim 15, wherein the fastener is a screw having an upper portion anda lower portion, wherein the upper portion is disposed in the panelflooring member and extends substantially the entire thickness of thepanel flooring member, and wherein the lower portion threadably engagesone of the ribs of the corrugated member.
 21. The flooring system ofclaim 20, wherein the panel flooring member includes a through holeextending from the top side to the bottom side, wherein the screwincludes in serial flow relationship a head disposed in the through holeand countersunk in the top side of the panel flooring member, a pair ofopposing upper wings disposed in the through hole, a threaded portionthreadably engaged with the one rib but not threadably engaged with thepanel flooring member, a pair of locations of broken-off opposing lowerwings, and a drill bit disposed below the one rib, wherein the throughhole has a diameter below the upper wings which radially extends morethan the drill bit, at least as much as the threaded portion, and lessthan the upper wings, and wherein the upper wings radially extend morethan the threaded portion and less than the head.
 22. The flooringsystem of claim 21, wherein the screw has a length which is less thanthe thickness of the panel flooring member plus the height of the onerib.
 23. A method for installing a flooring system comprising the stepsof: a) obtaining a corrugated member having a plurality of substantiallyparallel and longitudinally extending ribs and valleys, wherein thecorrugated member contains metal, wherein each valley has a bottom, andwherein each rib has a substantially equal height above the bottom ofeach adjoining valley; b) obtaining a panel flooring member having topand bottom sides, wherein the panel flooring member has a substantiallyconstant thickness; c) disposing the panel flooring member over and incontact with the corrugated member with the bottom side of the panelflooring member contacting a multiplicity of the ribs of the corrugatedmember; d) obtaining a screw including in serial flow relationship acounter-sinkable head, a pair of opposing upper wings, a threadedportion, a pair of opposing lower wings, and a drill bit, wherein thelower wings radially extend more than the drill bit, at least as much asthe threaded portion, and less than the upper wings, and wherein theupper wings radially extend more than the threaded portion and less thanthe head; and e) attaching the panel flooring member to one of the ribsof the corrugated member using the screw by inserting the screw firstinto the top side of the panel flooring member, then out through thebottom side of the panel flooring member, and then into the one rib ofthe corrugated member with the threaded portion threadably engaged withthe one rib.
 24. The method of claim 23, wherein the screw has a lengthwhich is less than the thickness of the panel flooring member plus theheight of the ribs.
 25. The method of claim 23 also including, afterstep e), exposing the top side of the panel flooring member to at leastone of walking floor traffic and rolling floor traffic.
 26. The methodof claim 23, wherein the lower wings are adapted to remain intact in thepanel flooring member and to break off upon encountering the one rib ofthe corrugated member.
 27. The method of claim 23, wherein the lowerwings are adapted to remain intact while passing through only a portionof the panel flooring member and to break off in the panel flooringmember before encountering the one rib of the corrugated member.
 28. Aflooring system comprising: a) a corrugated member having a plurality ofsubstantially parallel and longitudinally extending ribs and valleys,wherein the corrugated member contains metal, wherein each valley has abottom, and wherein each rib has a substantially equal height above thebottom of each adjoining valley; b) a panel flooring member having topand bottom sides, wherein the panel flooring member has a substantiallyconstant thickness, wherein the panel flooring member is disposed overand in contact with the corrugated member with the bottom side of thepanel flooring member contacting a multiplicity of the ribs of thecorrugated member, and wherein the panel flooring member includes athrough hole extending from the top side to the bottom side; and c) ascrew including in serial flow relationship a head disposed in thethrough hole and countersunk in the top side of the panel flooringmember, a pair of opposing upper wings disposed in the through hole, athreaded portion threadably engaged with one of the ribs of thecorrugated member but not threadably engaged with the panel flooringmember, a pair of locations of broken-off opposing lower wings, and adrill bit disposed below the one rib, wherein the through hole has adiameter below the upper wings which radially extends more than thedrill bit, at least as much as the threaded portion, and less than theupper wings, and wherein the upper wings radially extend more than thethreaded portion and less than the head.
 29. The flooring system ofclaim 28, wherein the screw has a length which is less than thethickness of the panel flooring member plus the height of the one rib.30. The flooring system of claim 28, wherein the top side of theflooring panel member is exposed to at least one of walking floortraffic and rolling floor traffic.